Sustainable coated corrugated fiberboard container

ABSTRACT

A packaging container having sustainable repulpable/recyclable capability specifically sized to maintain the integrity of the Meal, Ready-to-Eat (MRE) rations used by the U.S. Army and military services. A coated corrugated fiberboard using a C-flute configuration is utilized in a novel packaging design that incorporates a liner or a vertical container divider.

RELATED APPLICATIONS

This application is a Continuation of U.S. Patent Application entitled “Sustainable Coated Corrugated Fiberboard Container”, filed Sep. 30, 2010 and given U.S. Ser. No. 12/923,644.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was developed under funding of U.S. Army Contract No. W911QY-08-P-0440 and may be used for any U.S. Government Purpose without any royalty paid thereon or therefor.

FIELD OF THE INVENTION

The present invention relates to packaging, and in particular, coated corrugated fiberboard secondary packaging for the United States Anny rations known as Meal(s), Ready-to-Eat (MREs).

BACKGROUND OF THE INVENTION

Corrugated fiberboard is a well-known structural material commonly used for manufacturing storage boxes. The relatively inexpensive cost of the material, its structural qualities, and the ease with which corrugated fiberboard can be fabricated has resulted in an ever growing number of items manufactured from it. The use and development of this material in the manufacturing of containers is well known.

Moreover, recent concerns regarding the environmental impact of waste materials has led to greater demand for systems that promote sustainability and offer additional recycling options. Manufacturers of consumer goods now place a high priority on sustainable systems that incorporate recyclable and repulpable packaging designs in order to reduce environmental impacts. Additionally, recent regulations regarding the disposal of wax coated or impregnated packaging materials have increased the demand for recyclable and repulpable packaging systems that perform in wet and/or humid environments.

For example, in 2006, the Wal-Mart® Corporation initiated an ambitious packaging initiative to reduce packaging by 5% throughout its global supply chain before 2013. This effort centers around a packaging scorecard that rates suppliers and their products based on packaging innovations, environmental standards, energy-efficiencies and use of materials. The packaging scorecard utilizes packaging metrics that assess new consumer goods products and its packaging. Each packaging metric has potential economic and environmental benefits throughout the supply chain and therefore drives product design and innovation towards more eco-friendly product solutions. The rating system provides Wal-Mart® with a powerful measuring tool used to identify a superior product or design and also helps suppliers continuously improve their products and operations towards a more sustainable position.

Most recently, corrugated fiberboard structures have been investigated as replacements for the “Solid Fiberboard”, SF-grade, military only, fiberboard secondary packaging (ASTM 4727) in the Meal(s), Ready-to-Eat (MREs) packaging system used by the U.S. Army. What is needed is a high-performance, lightweight and recyclable material for secondary packaging systems for military rations. This new generation of containerboard structures offers numerous benefits over current packaging. Sustainable packaging technologies such as biodegradable additives, repulpable fiberboard coatings, effective design solutions and enhanced end-of-life disposal capabilities assist in reducing negative environmental impacts and further reduce the logistical footprint of military rations. Incorporating these solutions into ration systems additionally decreases overall packaging waste, enhances recyclability and creates a viable means of disposal for military rations. In addition, these corrugated board structures can offer excellent protection during transport, storage and operational use.

Numerous Executive Orders for “Greening the Government” have been issued to help conserve the environment and its natural resources through, for example, waste prevention, energy management, recycling and acquisition of bio-based products. Government agencies such as the Environmental Protection Agency, United States Forestry Service, and Department of Defense (DOD) operate extensive research programs that are focused on preserving natural resources through scientific research and effective resource management.

In this regard, the aforementioned SF-grade solid fiberboard material currently used in the Meal(s), Ready-To-Eat (MRE)) ration system is costly to produce and is more expensive than common commercial grades of fiberboard. This fiberboard material utilizes cellulose and harmful chemicals, thereby depleting natural resources in the environment and creating harmful waste. The additives enhance the durability of the packaging and adequately protect its contents but limit recyclability. Moreover, the current MRE container design must incorporate multiple manufacturing processes adding to the overall cost. Current research indicates that coating commercial grade corrugated fiberboard eliminates the need for the solid fiberboard, SF-grade material currently in use for ration containers and enhances recyclability by incorporating repulpable coated structures that may be used anew in the manufacture of fiberboard. Additionally, these containers may be manufactured in the same facility, thereby reducing their manufacturing and transportation cost and minimizing their carbon footprint.

Secondary packaging serves a vital role in protecting military rations during transportation, long-term storage and use. Ration shipping containers play an integral role in maintaining a high level of food quality and must perform in even the most severe climate conditions. Research and development in secondary packaging has led to the advancement of lightweight fiberboard and recyclable structures that have shown performance capabilities similar to current MRE containers. An innovative coated corrugated fiberboard container is described in this application utilizing environmentally friendly water resistant coatings that support composting, and recycling as viable means of disposal and recovery. The structural design of the ration containers offers a unique construction that reduces fiberboard material and eliminates the need for additional interior packaging.

SUMMARY OF THE INVENTION

The present invention incorporates high-performance, lightweight and recyclable coated corrugated fiberboard material into secondary packaging for military rations wherein a polymeric coated wax alternative medium (WAM) corrugated structure is utilized in lieu of the previous SF-grade fiberboard design. This new generation of fiberboard containers offers numerous benefits over current materials and is environmentally sustainable, utilizing repulpable coatings, and its effective design and enhanced end-of-life disposal capabilities reduce negative environmental impacts. Logistically, the packaging is lighter yet capable of performing in adverse environments and will further reduce the environmental footprint of military rations. Packaging waste is reduced, recyclability is enhanced, and disposal options are increased. In addition, this fiberboard design offers comparable protection during transport, storage and operational use.

The container of the present invention is sized for the secondary packaging, storage, and transportation of a standard twelve-count case currently used in the Meal, Ready-To-Eat (MRE) ration system (ACR-M-030 Section D) as defined by the United States Department of Defense and the U.S. Army. It is compostable, recyclable, and repulpable with equal compression strength and less weight in comparison to the existing military packaging. In one embodiment, a two-piece container is provided, including a regular slotted container (RSC) with a separate corrugated insert or liner around its interior perimeter to provide additional support under load and to increase puncture resistance along the vertical walls of the container. In another embodiment, a one-piece RSC design is provided, including a built-in or integral divider across the width of the container subdividing it into two compartments of generally equal size, thereby increasing the structural rigidity of the container. The packaging is delivered in a generally flat, partially assembled state to the end-user, whereby it need only be expanded into its three-dimensional conformation in a standard manner, and in the case of the two-piece container, its liner inserted therein, in order to make the device ready for use after packaging it with twelve MRE rations.

It is an object of the invention to provide a coated corrugated fiberboard container sized for the Meal(s), Ready-To-Eat (MRE) ration system;

It is yet another object of this invention to provide a corrugated fiberboard container that is lighter, less expensive to manufacture, yet equal in durability to the currently used solid fiberboard containers used for the Meal(s), Ready-To-Eat (MRE) ration system;

It is still another object of this invention to provide a corrugated fiberboard container for the Meal(s), Ready-To-Eat (MRE) ration system which is easier to transport;

It is another object of this invention to provide a corrugated fiberboard container for the Meal(s), Ready-To-Eat (MRE) ration system which is environmentally friendly;

It is an object of this invention to provide a corrugated fiberboard container for the Meal(s), Ready-To-Eat (MRE) ration system that is recyclable and repulpable;

It is yet another object of this invention to provide a corrugated fiberboard container for the Meal(s), Ready-To-Eat (MRE) ration system that is recoverable; and,

It is an object of this invention to provide a corrugated fiberboard container for the Meal(s), Ready-To-Eat (MRE) ration system that is simple to manufacture, and with minimum waste.

The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the two-piece embodiment of the inventive container with its insert partially removed;

FIG. 2 is a perspective view of the invention shown in FIG. 1 with insert in place;

FIG. 3 is a perspective view of the one-piece embodiment with integral divider of the inventive container;

FIG. 4 is a top plan view of the primary die-cut sheet of the container shown in FIGS. 1 and 2;

FIG. 5 is a top plan view of the die cut sheet of the insert of the container shown in FIGS. 1 and 2;

FIG. 6 is a top plan view of the die cut sheet of the container shown in FIG. 3;

FIG. 7 is a partially collapsed perspective view of the two-piece embodiment shown in FIGS. 1 and 2;

FIG. 8 is a partially collapsed perspective view of the one-piece divider container shown in FIG. 3;

FIG. 9 is a table showing the industry standards and testing methods that the inventive containers have been evaluated by;

FIG. 10 is a bar graph which graphically shows the performance at a fixed temperature and humidity of the containers of this invention compared to the MRE container currently in; and

FIG. 11 is a table showing base weight analysis of presently used solid fiberboard compared with the regular slotted two piece container of FIG. 1 and the regular slotted container with divider of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

While the invention is described in connection with certain preferred embodiments, it is not intended that the present invention be limited to said embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalent arrangements as may be included within the spirit and scope of the invention as defined by the appended claims.

This invention may be constructed from any corrugated board-like material that is amenable to precision cutting and is easily foldable. In preferred embodiments, the invention is manufactured from coated corrugated fiberboard.

The preferred embodiments of the apparatus and best mode are rendered in FIGS. 1 through 8 and their performance relative to their counterparts currently in use are depicted in FIG. 10. FIGS. 1, 2, 4-5, and 7 depict the two-piece embodiment of the current invention which is a slotted container with an insert that wraps around the perimeter of the container footprint. FIGS. 3, 6, and 8 depict the one-piece embodiment of the current invention, which is a slotted container with an integral width divider. When applicable, the elements described herein apply to both the aforementioned embodiments. Both embodiments are manufactured with a polymeric coated wax alternative medium (WAM) corrugated structure. The corrugated container designs only necessitate a single manufacturing center which lowers manufacturing and transportation costs and additionally lowers the carbon footprint.

The containers are preferably constructed from corrugated fiberboard consisting of 55 pound or 69 pound linerboard facings with a 30 pound corrugating medium material forming a balanced single wall C-flute structure. A water-resistant coating is applied to the linerboard facing material, for example, coatings manufactured under the Spectra-Guard™ name by the Spectra-Kote™ Corporation, in particular its sg48m™ coating. Additionally, WAM is applied to the 30 pound fiberboard forming the C-flute structure of the preferred fiberboard material in order to improve its water resistance. In the first embodiment disclosed infra., an additional corrugated insert having a B-flute structure forms the interior liner.

A first preferred embodiment is depicted in FIGS. 1, 2, 4-5, and 7 forming a regular slotted container (RSC) specifically sized to accommodate twelve assembled MRE rations. The two-piece container 100 of the present invention is assembled from the aforementioned corrugated fiberboard material. FIG. 1 shows the two-piece container 100 fully erect with its liner 104 partially removed from its base container 103. FIG. 2 shows the base container 103 with liner 104 inserted and ready for use.

FIGS. 4 and 5 show the base container 103 and liner 104 of this preferred embodiment formed from the two-piece container die cutout 101 and liner die cutout 102. Thickened lines indicate score lines or creases created, for example, by embossing pressure or by a plurality of periodic incisions along the desired crease. The two-piece container base die cutout 101 is generally approximately 57 inches in length and approximately 20 inches in width. Elements of the cutout 101 include a first long sidewall 10 that is generally rectangular in shape and measures approximately 17⅛ inches by approximately 9¼ inches. Adjacent the short dimension of the first sidewall 10 and separated by a score or crease is a first short end wall 14 that is also generally rectangular in shape measuring approximately 10 11/16 inches by approximately 9¼ inches. Adjacent this end wall (i.e., first short end wall 14) are a generally rectangular second long sidewall 12 and generally rectangular second short end wall 16, respectively. The second long sidewall 12 measures approximately 17 3/16 inches by approximately 9¼ inches and the second short end wall 16 measures approximately 10⅝ inches by approximately 9¼ inches such that when erect, the assembled two-piece primary container 103 measures approximately 9¼ inches in height, approximately 17 3/16 inches in length, and approximately 10 11/16 in width. Top and bottom flaps are formed adjacent the sidewalls described supra wherein first long sidewall top and bottom flaps 11 measure approximately 17⅛ inches by approximately 5⅜ inches, first short end wall top and bottom flaps 15 measure approximately 10 11/16 inches by approximately 5⅜ inches, second long sidewall top and bottom flaps 13 measure approximately 17 3/16 inches by approximately 5⅜ inches, and second short end wall top and bottom flaps 17 measure approximately 10⅝ inches by approximately 5⅜ inches. When erect, the two-piece primary container 103 forms a generally rectangular structure measuring approximately 9¼ inches in height, approximately 17 3/16 inches in length, and approximately 10 11/16 inches in width. Clearance slots 18 are formed in the two-piece container die cutout 101 between flaps 11, 13, 15, and 17 to reduce impingement when the two-piece primary container 103 is assembled. Additionally, bevel ended assembly flap 19 measuring approximately 9¼ inches by approximately 1⅜ inches is provided to facilitate securing the first long sidewall 10 to the short end wall 16 during assembly of the device 100.

FIG. 5 depicts the liner die cutout 102 forming the liner 104 of the two-piece container 100. The liner die cutout 102 is generally rectangular and approximately 54½ inches in length and approximately 8¾ inches in width. A liner first long sidewall 20 measures approximately 16⅞ inches by approximately 8¾ inches and adjacent the short dimension or ends of the sidewall 20 are identical liner short end walls 22 measuring approximately 10⅜ inches by approximately 8¾ inches. Finally, a sectioned liner second long sidewall is formed from identical liner second long sidewall sections 21 formed adjacent the distal ends liner short end walls 22, each measuring approximately 8 7/16 inches by approximately 8¾ inches. When assembled, the free ends of the liner second long sidewall sections 21 abut against one another when the liner 104 is inserted into such that the combined length of said liner second long sidewall elements 21 are equivalent to the length of the liner first long sidewall 20.

As shown in FIG. 7, the two-piece container 100 of the present invention is assembled for flat shipping by securing assembly flap 19 of the two-piece container die cutout 101 to its second short sidewall 16 by adhesive or other means whereby the two-piece container 100 can be shipped to the user in a generally flat conformation. When needed, the now partially assembled two-piece primary container 103 is simply expanded into its three dimensional conformation and one set of flaps 11, 15, 13, and 17 folded inward and secured to maintain the container 103 in an erect position. Liner 104 is thereafter inserted to increase the rigidity of the entire two-piece container 100, and the MRE rations are loaded therein. Thereafter, the remaining set of flaps 11, 15, 13, and 17 are folded inward and secured to thereby seal the two-piece container 100.

In a second embodiment depicted in FIGS. 3, 6, and 8, a one-piece container 110 is depicted wherein a slotted container is formed with an integral divider sized to accommodate MRE rations. FIG. 3 shows the one-piece container 110 and divider of the present invention fully assembled with its divider in place.

As shown in FIG. 6, the one-piece container 110 of this embodiment is formed from the one-piece container die cutout 111 as shown. Thickened lines indicate score lines or creases created, for example, by embossing pressure or by a plurality of periodic incisions along the desired crease. The one-piece container die cutout 111 is generally approximately 69 inches in length and approximately 20 inches in width. Elements of the cutout III include a one-piece cutout first long sidewall 40 that is generally rectangular in shape and measures approximately 17 3/160 inches by approximately 9¼ inches. Adjacent each short dimension or end of this first sidewall 40 are identical one-piece cutout short end walls 42, each end wall 42 being generally rectangular in shape and measuring approximately 10 11/16 inches by approximately 9¼ inches. Adjacent one one-piece cutout short end wall 42 is a one-piece cutout long sidewall first section 44 measuring approximately 9⅞ inches by approximately 9¼ inches. A one-piece cutout second long sidewall second section 46 measuring approximately 8 11/16 inches by approximately 9¼ inches is formed adjacent the distal end of the other one-piece cutout short end wall 42 such that said first section 44 and said second section 46 combine to form the second long sidewall of the one-piece container 110 when assembled. Top and bottom flaps are formed adjacent the sidewalls described supra with the one-piece cutout first long sidewall top and bottom flaps 41 measure approximately 17 3/16 inches by approximately 5⅜ inches, one-piece cutout short end wall top and bottom flaps 43 measure approximately 10 11/16 inches by approximately 5⅜ inches, one-piece cutout second long sidewall first section top and bottom flaps 45 measure approximately 9⅞ inches by approximately 5⅜ inches, and one-piece cutout second long sidewall second section top and bottom flaps 47 measure approximately 8 11/16 inches by approximately 5⅜ inches. When erect, the one-piece container 110 forms a generally rectilinear structure measuring approximately 9¼ inches in height, approximately 17 3/16 inches in length, and approximately 10 11/16 inches in width. A divider 48 is formed adjacent the one-piece cutout second long sidewall second section 46 and measures approximately 10½ inches by approximately 9¼ inches. Finally, a one-piece container assembly and flap 49 measuring approximately 9¼ inches by approximately 1⅜ inches is provided to facilitate assembly and stability for the divider 48 and is formed adjacent the divider 48 to engage the inner surface of sidewall 40. As in the two-piece container 100 above, clearance slots 18 are formed between top and bottom flaps 47, 43, 41, and 45 to reduce impingement when the one-piece container 110 is assembled.

The benefit of the inventive coated corrugated MRE container is that it is compostable, recyclable, repulpable with equal compression strength and has less weight in comparison to the existing MRE military rations packaging system. This is presented in Table 1 (see FIG. 11). One common specification for paperboard is the calculation of basis weight or grammage which is the mass of paper per unit area. Paper is bought, sold and often defined in accordance with its mass per unit area, and therefore the basis weight has significance both in defining price and performance. The values of many physical properties such as thickness and bulk are interpreted and specified with regard to the particular grammage involved.

In Table 1 (FIG. 11), the letters MRE SF represent the presently used solid fiberboard (SF grade) military container while the letters RSC IN define the regular slotted container (RSC) of the two piece container (FIG. 1) while the letters RSC WD stand the regular slotted container (RSC) of the container with divider (FIG. 3).

As shown in FIG. 8, the one-piece container 110 of the present invention is assembled for flat shipping by securing the free end of the one-piece cutout second long sidewall first section 44 to the one-piece cutout second long sidewall second section 46 such that their combined lengths are about equal to the 17 3/16 inches length of the one-piece cutout first long sidewall 40, making sure that divider 48 is positioned towards the interior of the one-piece container 110. The assembly flap 49 is secured to the interior surface of the one-piece cutout first long sidewall 40 at its midline such that, when assembled, two identical spaces are defined. The container 110 is now ready for flat shipping. When needed, the partially assembled one piece container 110 is simply expanded into its three dimensional configuration and one set of flaps 47, 43, 41, and 45 folded inward and secured to maintain the one-piece container 110 in its erect conformation. The twelve rations MRE are loaded therein and the remaining set of flaps 47, 43, 41, and 45 are folded inward and secured to thereby seal the one-piece container 110.

FIG. 9 shows in tabular form the industry standard testing methodologies that the containers of the present invention have been subjected to. As shown in FIG. 10, performance of the corrugated fiberboard containers of the present invention has comparable performance to the current MRE packaging. Testing indicated that MRE packaging noted therein would have suffered no adverse outcomes. FIG. 10 shows graphically the results of compression studies wherein under standard and wet conditions, the corrugated fiberboard containers of the present invention showed similar and even higher compression values over the current solid fiberboard ration systems. Rain chamber testing at high intensity for up to eight hours have also demonstrated that the water resistant coatings are capable of repelling water and recovering compression capability after exposure to wet environments. Cold weather studies have also demonstrated that the containers of the present invention withstand high moisture conditions in cold weather conditions, yet retain overall packaging containment and integrity. The containers maintain their integrity even after encountering material handling and transportation hazards, for example shock, vibration, and static/dynamic compression. They are able to withstand cross country shipment, including via road, rail, and sea, and are able to sufficiently protect their contents when subject to various low velocity and high velocity impacts such as those encountered during aerial delivery of military rations.

The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention should not be construed as limited to the particular embodiments which have been described above. Instead, the embodiments described should be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the scope of the present invention as defined by the following claims: 

1-20. (canceled)
 21. An environmentally friendly container for Meals Ready to Eat rations comprising: corrugated fiberboard material being coated with a wax alternative medium coating (WAM) and the corrugated fiberboard material forming generally rectangular opposing sidewalls; corrugated fiberboard material being coated with a wax alternative medium coating (WAM) and the corrugated fiberboard material forming generally rectangular opposing end walls positioned adjacent said opposing sidewalls; fluted corrugated fiberboard material being coated with a wax alternative medium coating (WAM) and the fluted corrugated fiberboard material forming bottom flaps adjacent a side edge of said opposing sidewalls and said opposing end walls, said bottom flaps being inwardly folded; said opposing sidewalls and said opposing end walls and said bottom flaps defining a chamber therein; a one piece liner of fluted corrugated fiberboard material being coated with a wax alternative medium coating (WAM) and the one piece liner of fluted corrugated fiberboard material is seated adjacent the interior perimeter of said chamber defined by said opposing sidewalls and said opposing end walls and said bottom flaps, said one piece liner comprising a long side section, equal width end sections connected to and positioned adjacent each end of said long side section and a smaller side section connected to the distal end of each of said end sections, each smaller side section being of equal width; and, fluted corrugated fiberboard material being coated with a wax alternative medium coating (WAM) and said fluted corrugated fiberboard material forming top flaps connected to and positioned adjacent the top edge of said opposing sidewalls and opposing end walls, said top flaps being inwardly foldable to seal the container; wherein the container is compostable, recyclable and repulpable; wherein the container is about 9¼ inches in height, about 17 3/16 inches in length, and about 10 11/16 in width when sealed; wherein the flaps, end walls and sidewalls are a C-fluted corrugated fiberboard material and the liner is a B-fluted corrugated fiberboard material; and wherein the coated corrugated fiberboard material further comprises linerboard facings selected from the group consisting of 55 LB linerboard and 69 LB linerboard sandwiching 30 LB linerboard material forming a standard C-flute structure.
 22. A container for rations as claimed in claim 21 wherein said container may be selectively collapsed into a generally flat conformation. 